Characterization of graphite and ZrO2 reinforced aluminium metal matrix composite for enhanced mechanical properties in electronics applications

Abstract The objective of this work is to examine the wear properties of a hybrid Metal Matrix Composite (MMC) consisting of 92 weight percent (wt%) Aluminium Alloy 6061 (AA6061), 2 wt% Graphite (C), and 6 wt% Zirconium Dioxide (ZrO 2 ). It was previously determined that this composition was ideal for improved metallurgical and mechanical properties. Nine specimens of the same composition were fabricated for this continuation work and put through wear tests with different applied load, sliding velocity, and sliding distance settings. To evaluate the performance of the composite, measurements were made of the wear rate and Coefficient of Friction (COF). According to the results, the wear rate typically increased as the applied load and sliding velocity increased. At the lowest load (10 N) and velocity (2 m s −1 ), the lowest wear rate (50.90 μg) and COF (0.197) were noted. Specimens with lower wear rates had smoother surfaces and less wear, as revealed by SEM analysis of the worn surfaces; specimens with higher wear rates showed more significant surface damage, such as deeper cuts and serrations. In specimens with less wear, XRD analysis verified the presence of crystalline aluminium, indicating a strong correlation between wear resistance and the crystalline structure of the composite. Linear regression equations were created to predict wear behavior under different conditions. According to the results, the composite’s wear characteristics are greatly influenced by the sliding velocity and applied load. ZrO 2 and C together have lubricating and strengthening properties that, under certain circumstances, reduce wear. The composite exhibits potential for usage in electronics applications, especially in components where wear resistance and mechanical durability are critical due to its favorable wear characteristics and mechanical properties.